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Rubber Coupling and Sprocket Failures in Cement Mill Elevator

By Case Study

IDENTIFIED FAILURES

INDUSTRY

Cement

ASSET

Silos Feeding Elevator

PROBLEM

Damaged rubber coupling
and worn sprockets

AVOIDED

Unplanned Stoppage

Loss of production

IMPORTANCE OF THE SILOS FEEDING ELEVATOR IN CEMENT PRODUCTION

The Silos Feeding Elevator plays a crucial role in the cement production process, particularly in the stage where raw materials such as clinker, gypsum, and additives are transported to the mill. It ensures´the consistent and efficient delivery of materials to the cement mill, which directly influences the overall production efficiency, material handling, and energy consumption.

 

IDEAL FUNCTIONING OF THE SILOS FEEDING ELEVATOR

Under optimal conditions, the Silos Feeding Elevator operates with uniform speed and precise material feeding, ensuring a continuous and smooth supply of materials to the cement mill. This helps in maintaining a steady grinding process and contributes to the consistent quality of the cement.
The elevator system should have minimal mechanical stress, with effective lubrication, proper alignment, and condition monitoring to avoid irregular wear on the components. Regular maintenance and condition monitoring are essential to ensure uninterrupted operation and prevent material flow disruptions, which can impact the  efficiency of the entire cement production line.

 

MECHANICAL TRANSMISSION FAILURES: DAMAGED RUBBER COUPLING AND WORN SPROCKETS

The detection of a damaged rubber coupling and worn sprockets highlighted mechanical transmission vulnerabilities. The rubber coupling, which connects rotating shafts while damping vibrations and compensating for misalignments, had deteriorated, potentially due to misalignment, overload, or material fatigue, resulting in impaired torque transmission and increased mechanical stress.
Simultaneously, the sprockets, essential for driving chain-based power transmission, showed signs of tooth wear and deformation. This condition can cause chain slippage, irregular motion, and excessive vibration. The combined degradation of these components compromises the efficiency, reliability and longevity of the cement mill’s drive system, underlining the necessity of timely inspection and replacement to prevent unplanned failures and ensure stable mill operation.

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    06/05/2025
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    Kiln Crank Effect

    By Case Study

    IDENTIFIED FAILURES

    INDUSTRY

    Cement

    ASSET

    Kiln

    PROBLEM

    Crank Effect

    AVOIDED

    Unplanned Stoppage

    Kiln permanent deformation

    The rotary kiln is essential in cement production, transforming raw materials into clinker through high-temperature processing. Ideally, it rotates smoothly to ensure uniform heat distribution, which is crucial for efficient chemical reactions and high-quality clinker production.
    A major issue affecting kiln operation is the kiln crank effect, caused by uneven thermal expansion. This leads to deformation, irregular rotation, and mechanical stress on critical components, increasing wear, power consumption, and potential structural damage. Proper maintenance and temperature control are key to preventing these issues.

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      10/03/2025
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      CIGRE 2024 Paris

      By News

      The Biennial Session is held in Paris, France in even number years. It is the number one global power system event in the world, bringing together some 9000 power industry participants from over 100 countries, including 3600 international experts and other decision-makers. This is a unique weeklong interactive opportunity. Over 160 working meetings, over 30 Study Committee sessions and 800+ technical papers spanning the end-to-end power system.

      Once again we are be heading to CIGRE in the day 25 to 30 of August. You can visit us on the Stand Nr. 1P40.

      Do you want to know more about this? Meet Us there.

       

      #innovative #accurate #simple #non-invasive #predictive #maintenance #online #remote #monitoring #intelligencefortomorrow

      20/08/2024
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      Data Engineer

      By Job Offer

      Company description

      Engineering company specialized in the development of innovative products for monitoring industrial equipment. Today, the company has large industrial players in the Iberian Peninsula as clients and intends to grow to become a world reference in offering technological solutions for an industry.

      Description of functions

      The company searches for a collaborator based in Engineering for its ML/AI department, with the personnel taste for data analysis and algorithms development. This person will work directly with R&D and Administration team in a business role with great growth potential.

      Main functions to develop:

      • Data analysis
      • ML/AI
      • Development of new technological algorithms

      Main requirements for a role:

      • Engineering knowledge base (electrical preferred)
      • Strong knowledge of phyton programming
      • High communication skills (oral and written) and auto-critical ability
      • Autonomy and results orientation
      • Proficiency in English

      Essential requirements:

      • Knowledge of rotating machines and transformers
      • Pleasure to deal with technological products and technical engineering complexity

      Valuable Aspects:

      • Knowledge of Labview
      • Knowledge of Matlab

      Remuneration

      Negotiation of agreed goals and demonstrated experience.

      This could be your opportunity
      Send us your application to geral@enging.pt

      23/05/2022
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      Backend Dev Engineer

      By Job Offer

      Does new technology excite you?
      Enging – Make Solutions should be your workplace!

      Started in Portugal in 2011, Engineering company focused on developing innovative and disruptive products for real time monitoring of electric machines. Today has as client’s major industrial players and intends to grow to become a world reference in offering predictive maintenance technological solutions.

      The company is looking for a BackEnd Dev Engineer for the industry sector to develop its web platform. This person will work directly with the R&D team and work to increase the company’s great growth potential.

      Main functions to develop:
      • Support in the implementation of the company’s operational objectives
      • Definition and implementation of new developments

      Main requirements for the role:
      • Engineering knowledge base (informatics preferred)
      • Experience in similar roles
      • High communication and critical capacity
      • Autonomy and results orientation
      • Proficiency in English
      • A clear understanding of Object Oriented Programming (OOP)
      • Create testable code and prioritize testing

      Essential requirements:
      • 2+ years of Javascript experience (TypeScript, React.js, Node.js, MongoDB stack)
      • API design and development
      • User interface development
      • Experience in microservices architectures
      • Experience in database design and programming (MongoDB preferred)
      • Knowledge of object storage (Preferred MinIO)
      • Knowledge of message brokering tools (RabbitMQ preferred)
      • Knowledge of test frameworks (jest, jasmine, karma, mocha, etc.)
      • Experience with version control and CI/CD software
      • Experience in deploying applications on local and/or external networks
      • Experience with containerized applications (Docker)

      Valuable Aspects:
      • Full-Stack Development
      • Semantic documents in HTML5 and CSS
      • Kubernetes
      • Virtual Machines & Server Management
      • Computer Networks
      • Linux Management
      • Management of distributed database architectures (MongoDB)
      • Backup Management (DBs & VM’s)

      This could be your opportunity
      Send us your application to geral@enging.pt

      26/04/2022
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      World WaterTech Summit North America 2021

      By News

      World Water Tech has established itself as a meeting place for international stakeholders focused on advancing the commercialisation of advanced water and wastewater solutions in London and North America.

      It is with great pleasure that we announce our virtual presence at the World Water Tech North America Summit.

      Do you want to know more about this?

      Meet Us there.

       

      #insideenging #worldwatertechnorthamerica #innovative #accurate #simple #noninvasive #predictive #maintenance #online #remote #monitoring #intelligencefortomorrow

      06/10/2021
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      CIRED 2021 – 26th International Conference and Exhibition on Electricity Distribution

      By News

      The 26th International Conference and Exhibition on Electricity Distribution – CIRED (International Conference and Exhibition on Electricity Distribution) will be held virtually this year, and will start on September 20th, providing all interested parties the opportunity to participate in this event.
      CIRED 2021 gives all participants an opportunity to hear about new research, ideas and initiatives; and interact with hundreds of key decision-makers in the electricity distribution field.

      It is with great pleasure that we announce our virtual presence on CIRED. We will also have the opportunity to present a paper developed by our R&D director, Jorge Estima.

      Do you want to know more about this? Meet Us there.

       

      #insideenging #CIRED #innovative #accurate #simple #non-invasive #predictive #maintenance #online #remote #monitoring #intelligencefortomorrow

      02/09/2021
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      Business Development Manager

      By Job Offer

      Does new technology excite you?
      Enging – Make Solutions should be your workplace!

      Started in Portugal in 2011, Engineering company focused on developing innovative and
      disruptive products for real time monitoring of electric machines. Today has as client’s major
      industrial players in the Energy sector and intends to grow to become a world reference in
      offering predictive maintenance technological solutions.

      The company is looking for a Business Development Manager for renewable sector with
      proven track record in selling business solutions to large utilities customers. This person will
      work directly with the management team and share the leadership of a key business function
      with great growth potential.

       

      KEY RESPONSIBILITIES

      • Support the company’s business development strategy
      • Customer acquiring and management
      • Identifying, qualifying, and managing multiple opportunities at once
      • Definition, management and negotiation of commercial contracts with customers, distributors or other business partners in its markets
      • Identification of new growth opportunities
      • Planning, preparing and giving presentations and capability demonstrations
      • Support the implementation of new marketing initiatives

      QUALIFICATIONS, SKILLS AND EXPERIENCE

      • At least 2 years’ experience in sales to b2b customers
      • Degree on Engineering or Management
      • Experience with large utilities companies (Preferential)
      • Consultative style with good negotiation skills
      • Autonomy and results orientation
      • Knowledge of Digital Transformation
      • Excellent written and spoken English and Spanish skills
      • Full Driving license
      • Current and valid passport

      BENEFITS

      • Flexible working hour model and workplace
      • Health insurance
      • Training
      • Company’s car and electronic means
      • Fixed component and a variable component money package connected to goals

       

      This could be your opportunity

      Send us your application to geral@enging.pt

      02/07/2021
      Love0

      Sales Engineer

      By Job Offer

      Does new technology excite you?
      Enging – Make Solutions should be your workplace!

      Started in Portugal in 2011, Engineering company focused on developing innovative and
      disruptive products for real time monitoring of electric machines. Today has as client’s major
      industrial players and intends to grow to become a world reference in offering predictive
      maintenance technological solutions.

      The company is looking for a Sales Engineer for industry sector to raise it business with
      industrial customers. This person will work directly with the commercial team and work to
      increase the company’s great growth potential.

       

      KEY RESPONSIBILITIES

      • Customer acquiring and management
      • Identifying, qualifying, and managing multiple opportunities at once
      • Identification of new growth opportunities
      • Planning, preparing and giving presentations

      QUALIFICATIONS, SKILLS AND EXPERIENCE

      • Like for sales
      • Degree on Engineering or Management
      • Consultative style with good negotiation skills
      • Autonomy and results orientation
      • Knowledge of Digital Transformation
      • Excellent written and spoken English and Spanish skills
      • Full Driving license
      • Current and valid passport

      BENEFITS

      • Flexible working hour model and workplace
      • Health insurance
      • Training
      • Fixed component and a variable component money package connected to goals

       

      This could be your opportunity

      Send us your application to geral@enging.pt

      02/07/2021
      Love0

      Wind Operations Europe 2021

      By News
      The production of energy from renewable sources has grown considerably in recent years, resulting in a significant increase in the installed capacity of wind power and number of turbines in service on-shore and off-shore. Turbine technologies, whether geared or direct drive, are rapidly evolving in terms of power and complexity, and there is an urgent need for cost effective operation and maintenance (O&M) strategies. Unplanned downtime represents one of the main cost drivers of wind farms.
      Electrical machines are usually reliable compared to other components such as drivetrain and gearboxes, but in the wind industry, generators have proven to be the cause of significant downtime. This is because their failure rate and downtime per failure, are unacceptably high.
      For this reason, ENGING has developed a specific solution, the PreditWindT, for the real-time monitoring of the main components of the power module in wind turbines, namely the generator, power electronics (frequency converter and soft starter) and transformer, that will allow operators to apply preventive maintenance strategies instead of corrective actions, with increased availability and significant operation cost savings.
      12/05/2021
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